A LEGACY OF LIFE-SAVING INNOVATION IN AVIATION
MARTIN-BAKER AMERICA, INC. MANUFACTURING
A LEGACY OF LIFE-SAVING INNOVATION IN AVIATION Martin-Baker America, Inc. is pioneering advancements in ejection seats and safety equipment, driven by a commitment to quality and a proven history of preserving pilots’ lives. Matthew Johnson, Vice President and General Manager, discusses the company’s mission to protect those who protect us Writer: Rachel Carr | Project Manager: Poppi Burke
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or over 80 years, Martin-Baker Aircraft Company (MartinBaker) has proudly been a world leader in the design and manufacture of ejection and crashworthy seats, with a remarkable history of saving more than 7,800 lives. Today, the company continues to thrive under the leadership of the Martin family – descendants of Founder Sir James Martin. Headquartered in Denham, England, Martin-Baker America, Inc. (MBAI) was established in 1999. It commenced operations the following year as a subsidiary of Martin-Baker to better serve its customers in the US market. North America Outlook Issue 37 | 3
MARTIN-BAKER AMERICA, INC. MANUFACTURING
As the corporate structure evolved and capabilities expanded within the US, it became an affiliate, allowing the manufacture and service of Martin-Baker products for the North American market. Employing 165 people across two main sites, with the majority working in the Johnstown, Pennsylvania plant, the area hosts a strong defense community, including companies such as Leonardo DRS, Concurrent Technologies Corporation (CTC), Lockheed Martin, and Kongsberg Defence & Aerospace AS. “At the Johnstown plant, we focus on manufacturing crashworthy helicopter seats for the US military and our global commercial and military customers,” introduces Matt Johnson, Vice President and General Manager. “Additionally, we produce components for both our helicopter and ejection seats in support of US military flight line maintenance and performing scheduled maintenance and unscheduled repair of ejection seats to support the US and Canadian militaries.” Moreover, at the Johnstown site, MBAI has all the necessary supplychain capabilities to source materials both domestically and internationally. “Our manufacturing capabilities include ejection seat maintenance, repair, and overhaul (MRO), parachute packing, computer numerical control (CNC) machining, industrial sewing, painting, assembly, and inspection. “This core set of skills allows us to build all Martin-Baker products to print with technical assistance provided by the design authority,” Johnson affirms. A second facility in Fort Worth, Texas, acts as the home base for field service activities and a training center for military fleet maintainers. From here, engineers are strategically deployed to Air Force and Naval bases to support customers and products in action. 4 | North America Outlook Issue 37
In crashworthy seating, MBAI produces seats for Blackhawk (H-60), Chinook (MH-47), Super Stallion (CH53), and the Poseidon (P-8). For the ejection seat market, meanwhile, the company provides spare parts and full-scale maintenance for Talon (T-38), Texan (T-6), Super Hornet (F-18), and Lightning II (F-35) aircraft. Additionally, it offers spare replacement parts for all seats, including cushions, fabrics, restraint harnesses, and other contact points.
ELEVATING EJECTION SEAT SAFETY There are varying but equally important strategies that MBAI deploys to ensure quality and safety. “Firstly, we have world-class design engineering that has been refined over many decades to treat the safety of pilot and maintainer as the highest priority. Each design has specific product safety reviews before being placed into the manufacturing stream,” Johnson outlines.
MARTIN-BAKER AMERICA, INC. MANUFACTURING
“I’m particularly proud of the work we’re doing with the F-35 program on the maintenance of our US16E ejection seat. Each seat must undergo a significant overhaul at the 10-year mark, and we are currently the only facility in the US capable of performing this work” – M AT T J O H N S O N , V I C E P R E S I D E N T A N D G E N E R A L MANAGER, MARTIN-BAKER AMERICA
CA N YO U E L A B O R AT E O N YO U R T I M E AT M A R T I N - B A K E R ? H O W H A S T H E I N D U S T RY C H A N G E D I N YO U R 24 Y E A R S O F S E RV I C E ? Matthew Johnson, Vice President and General Manager: “It has changed in a few ways, but workforce shortages and inflation have been felt in every industry since the COVID-19 pandemic. “The industry-specific changes can be attributed to increased Buy American government-backed initiatives and cybersecurity regulatory compliance. “The US Government is taking our data security very seriously, and I believe it would be hard to argue this isn’t for a good reason, but the new Cybersecurity Maturity Model Certification (CMMC) rules are making it very difficult to work with small domestic and foreign businesses of any kind. “The feel of the company hasn’t changed much. Of course, we’ve had to become more sophisticated over the years, both in the US and UK, but the changes and improvements are based on long-term relationships and views. “The Martin family is a fantastic group to work for. Each of the directors is actively engaged in running the business, and they always find time for you. “As I progressed through the company, I could feel that family culture all along the way, which is why I think so many employees complete their entire working careers here – I hope to be one of them.”
“The next approach is in supply chain selection. We only accept suppliers who can comply with strict aeronautical standards like AS9100 and can also meet tightly toleranced machining requirements necessary for precision equipment like an ejection seat.” This selection process, combined with robust incoming product inspection, ensures MBAI’s maintainers are only using the highest-quality products. “Our culture is rooted in quality and safety. There is a banner that hangs at the entrance to the plant stating, ‘Aircrew Safety Equipment, the only part of the aircraft that CANNOT fail!’” he tells us. “We treat this as a guiding statement for all things we do around the plant. Employees hold themselves and each other accountable to extremely high-quality work because they know that someone’s life depends on it.” Importantly, MBAI has a dedicated safety coordinator and safety council, and the team ensures working conditions are exceptionally safe and that foreign debris has no chance of entering critical workspaces. North America Outlook Issue 37 | 5
MARTIN-BAKER AMERICA, INC. MANUFACTURING
“There is tremendous pride that comes with this type of work, which is reflected in the cleanliness of the shop floor,” Johnson notes. Martin-Baker helicopter seats contain a special attenuation device that is designed to allow the seat to absorb the impact of a crash or hard landing rather than transfer that energy into the occupant. This critical technology has saved many soldiers’ spines. “The safety regulations are conveyed to us through military specifications which often prescribe the lowest acceptable safety factors. Martin-Baker designs incorporate additional margin-of-safety factors to ensure our customers receive the highest-quality product,” insights Johnson.
EMPOWERING THE NEXT GENERATION MBAI’s workforce development strategy is closely tied to the plant’s geography and Johnstown’s history. Once a major steel-producing town, Johnstown faced significant job losses when the steel industry declined in the early 1980s, leading to a steady drop in population. Throughout that time, the town’s economy continued to struggle. However, Congressman Jack Murtha became prominent on the Defense Appropriations Committee, advocating for Johnstown to be established as an industrial defense base. As a result, several large contractors set up operations there, including Martin-Baker. “As steel workers transitioned to defense jobs, many encouraged their children to pursue college and move to more prosperous areas of the country,” observes Johnson. Over the years, this left a limited pool of aging skilled workers. Recognizing the need to cultivate new talent, MBAI launched a high school apprenticeship program to transfer knowledge from its experienced workforce. 6 | North America Outlook Issue 37
R E VO L U T I O N I Z I N G P R O D U C T I O N By integrating cutting-edge technology into its manufacturing processes, MBAI is investing in automation. “We have invested in several automatic stitching machines that can perform some repetitive work. This helps tremendously by unburdening our sewing technicians so they can focus on the many jobs that cannot be automated. “There are a lot of 3D assemblies in our portfolio that don’t lend themselves to automation, so we’ll be training new technicians for many years to come,” Johnson provides. In terms of artificial intelligence (AI), the company sees huge potential in two applications – firstly, AI-driven vision systems that can ensure assemblies are made correctly where humans might otherwise miss a defect. “As you can imagine, even one defect in our product could be quite disastrous, so error-proof inspection is very desirable.” Secondly, data analytics – seat maintenance cycles can be difficult to manage, considering the movement of any given fleet and the funding cycles it experiences. “We take pride in getting the right parts to the right people at the right time, but there’s always room for improvement. We believe AI will help us make this task more efficient,” shares Johnson.
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METAIR.COM
Metropolitan Aircraft Parts, Inc.: A Trusted Partner Powering Aerospace Excellence For more than 50 years, Metropolitan Aircraft Parts, Inc. has provided precision hardware, fasteners, and supply solutions backed by responsive service and technical expertise. As a family-owned business based in West Babylon, New York, Metropolitan has built its reputation on reliability, integrity, and a commitment to helping customers keep production moving. Supporting some of the industry’s most respected aerospace manufacturers requires more than maintaining inventory. It demands a supplier that understands strict aerospace standards, responds quickly to changing production requirements, and consistently delivers dependable products with complete traceability. Metropolitan has gained that confidence by combining deep industry knowledge with a customerfirst approach focused on long-term partnerships. Metropolitan’s 25-year relationship with Martin-Baker America, Inc. demonstrates its ability to uphold those principles. During that time, the company has supplied critical aerospace hardware and components used in aircraft ejection seats and crashworthy helicopter seating systems—products where precision, consistency, and reliability are essential. Metropolitan’s ISO 9001:2008 and AS9120B certifications reflect the company’s dedication to maintaining robust management systems and meeting the rigorous requirements of the aerospace supply chain. These certifications underscore Metropolitan’s pledge to deliver dependable products and service that customers can rely on. As the aerospace industry continues to evolve, Metropolitan remains focused on the principles that have guided the company since its founding: integrity, responsiveness, and exceptional customer support. The company takes pride in building lasting relationships by providing personalized service, dependable delivery, and solutions tailored to each customer’s needs. Today, Metropolitan Aircraft Parts, Inc. continues to support leading aerospace manufacturers with the products, expertise, and service needed to meet today’s production demands and tomorrow’s challenges. Whether supplying missioncritical hardware or helping customers navigate complex supply chain requirements, Metropolitan remains dedicated to being a trusted partner every step of the way.
MARTIN-BAKER AMERICA, INC. MANUFACTURING
“We seized the chance to fill our labor pool with bright young minds and give our children an opportunity to stay in the place they call home prosperously. We decided to invest in our high school students and equip them for the future. This is how the high school apprenticeship program began,” Johnson reveals. Indeed, it is truly a grassroots effort from MBAI, which provides funding to ensure training is available and removes barriers to employment by providing free bus passes to students, but mostly, it’s successful because employees give back. “Our work culture is rooted in servant leadership, and many employees actively engage with local high schools to inform students about opportunities at MBAI. “We offer year-round tours and workshops for teachers, parents, and students to raise awareness about careers focused on our lifesaving equipment. Each summer, we interview students for eight to 8 | North America Outlook Issue 37
10 junior and senior apprenticeship positions,” he explains. During these months, the company supports students holistically, pairing them with mentors and offering training in job skills and financial management. Successful participants receive a certificate and help with resumes to boost their employability in the defense sector. “Of course, we keep the best candidates! Those who excel are offered jobs in our manufacturing
areas, launching their formal careers. As a lifelong Johnstown resident, this work is deeply rewarding,” Johnson impassions.
AT THE FOREFRONT OF FLYING In terms of projects, MBAI is very unique in its seat maintenance capabilities. “I’m particularly proud of the work we’re doing with the F-35 program on the maintenance of our US16E ejection seat. Each seat must
MARTIN-BAKER AMERICA, INC. MANUFACTURING
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“Our culture is rooted in quality and s a fe t y. T h e re i s a b a n n e r t h a t h a n g s a t t h e e n t r a n c e t o t h e p l a n t s t a t i n g , ‘A i r c r e w Safet y Equipment, the only part of the aircraft that CANNOT fail!’”
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– M AT T J O H N S O N , V I C E P R E S I D E N T A N D G E N E R A L M A N A G E R , MARTIN-BAKER AMERICA
undergo a significant overhaul at the 10-year mark, and we are currently the only facility in the US capable of performing this work,” Johnson acclaims. For the fleet, flight time is invaluable. The government has a limited inventory of spare seats, so they cannot afford to wait long while any seat is in maintenance. “If we don’t do our job as quickly as possible – obviously without sacrificing safety – the fleet may
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experience the dreaded aircraft on the ground (AOG). Our small but mighty team works extremely hard to ensure seats are serviced promptly,” explains Johnson. As the fleet size continues to grow, MBAI is working with prime contractors Lockheed Martin and BAE Systems to increase maintenance capacity further. The future is bright for the company and, as such, several near-term goals excite Johnson and the team.
“For one, we are starting a journey to engineer some of our own helicopter seat products. The details are of a competitive nature, so it’s under wraps for now, but we believe we are better positioned to meet the needs of the modern warfighter. “We are working diligently to reach both the military and commercial markets with some new ideas that we believe our customers will love. Martin-Baker is a very respected name in aircrew safety, so we’re very excited to help keep that legacy at the front of technology,” Johnson proudly concludes.
Tel: 814-262-9325 information@martin-baker.us
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